Polymeric cutting edge structures and method of manufacturing polymeric cutting edge structures

ABSTRACT

A functional polymeric cutting edge structure and methods for manufacturing cutting edge structures using polymeric materials are provided. A razor blade for use in a razor cartridge or a blade box for assembly in a razor cartridge frame may be formed using the present invention.

FIELD OF THE INVENTION

This invention relates to shaving razors and methods of manufacturingcutting edge structures, and more particularly to manufacturing cuttingedge structures such as shaving razor blades from a polymeric material.

BACKGROUND OF THE INVENTION

Razor blades are typically formed of a suitable metallic sheet materialsuch as stainless steel, which is slit to a desired width andheat-treated to harden the metal. The hardening operation utilizes ahigh temperature furnace, where the metal may be exposed to temperaturesgreater than about 1000° C. for up to about 20 seconds, followed byquenching, whereby the metal is rapidly cooled to obtain certain desiredmaterial properties.

After hardening, a cutting edge is formed generally by grinding theblade. The steel razor blades are mechanically sharpened to yieldcutting edges that are sharp and strong to cut through hair over anextended period of time. The continuous grinding process generallylimits blade shapes to have straight edges with a substantiallytriangular or wedge shaped profile (e.g., cross section). The cuttingedge wedge-shaped configuration typically has an ultimate tip with aradius less than about 1000 Ångstroms.

The advantage of this prior art method is that it is a proven,economical process for making blades in high volume at high speed. Itwould be particularly desirable if such a process could utilize lowercost materials for blade formation and also enable cutting edge profilesother than substantially triangular.

Blades with cutting edges made from a polymeric material are disclosedfor disposable cutlery or disposable surgical scalpels (e.g., U.S. Pat.No. 6,044,566, U.S. Pat. No. 5,782,852). Razor blades made frompolymeric material are disclosed in GB2310819A. The disadvantage of anyof the prior art polymer blades is that the process of making suchplastic blades is not suitable to create a cutting edge with a tipradius of less than 1 μm as required for cutting hair.

Generally, the prior art utilizes melt flow processing techniques. Themolten polymer of the prior art is injected into a cavity of a mold toolwhich is typically metal, but the polymer is generally too viscous(typically exceeding 100,000 centiPoise) to fully penetrate into thesub-micro-meter (e.g., less than 1 micrometer) dimensioned spacesrequired in a cavity to create razor blade edges. However, choosing alower viscosity material or increasing the injection pressure, which maybenefit penetration into sub-micro-meter dimensioned spaces, causes thepolymeric material to penetrate between the mating surfaces of the twohalves of the mould tool, known as “flashing,” and therefore therequired cutting edge tip radius cannot be achieved. A decrease ofviscosity of the polymeric material may also be obtained by heating thepolymeric raw material above the glass transition temperature, oftenexceeding 200° C. Furthermore, after filling the cavity, the fluidpolymeric material needs to be cooled to achieve a solid state, whichcauses shrinkage of the blade shape and rounding of the edge andtherefore the required cutting edge tip radius cannot be achieved.

Therefore, a need exists for better processes for cutting edgestructures made of polymer and more cost-effective methods of makingcutting edge structures for shaving razors having required tip radius,less variability in edge quality and sharpness to provide a comparableor improved shaving experience.

It is also desirable to find materials and processes that can formcutting edge structures having any shape, such as non-linear edgesand/or provide an integrated assembly.

SUMMARY OF THE INVENTION

The present invention provides a simple, efficient method formanufacturing one or more cutting edge structures, such as razor bladesfrom a polymeric material and a functional polymeric cutting edgestructure such as a razor blade. Moreover, some methods are suitable forproducing a plurality of such cutting edge structures, or “blade boxes”comprising a plurality of razor blades formed in a polymeric material tobe disposed as a single unit in a razor cartridge.

In one aspect, the method for manufacturing at least one cutting edgestructure includes providing a base structure of a first polymericmaterial, pressing at least one cutting edge template into the basestructure, removing the template to obtain a cavity in the basestructure, filling the cavity with a second material, the secondmaterial being a precursor for a polymeric material, curing the secondmaterial, and separating the base structure and the cured secondpolymeric material, the at least one cutting edge structure comprised ofthe cured second polymeric material. In one aspect of the invention, thesecond precursor material includes a monomer material, an oligomermaterial, or any combination thereof. The at least one cutting edgestructure can include a gothic arch, a roman arch, or one or moreundercuts and have a tip radius of less than 1 micrometer.

In another aspect of the present invention, the first polymeric materialincludes Poly (methyl methacrylate) (PMMA) or Polydimethylsiloxane(PDMS) and the second precursor material includes acrylic or epoxy basedmaterials. The viscosity of the second precursor material is less thanabout 10000 centiPoise.

In another aspect of the present invention, the base structure is onlyone part and the cavity is entirely comprised in a single part in thebase structure. A portion of the cavity is not enclosed by the basestructure after formation.

Further, at least one of the second precursor material, the cured secondpolymeric material and at least one side of the cavity is transparent toelectro-magnetic radiation at a wavelength in the range of 250 to 1500nanometers.

Additionally, the separating step of the present invention includesphysical or chemical removal of the base structure from the cured secondpolymeric material cutting edge structure. The first polymeric materialis compliant. The separated base structure may be reused at the fillingstep.

In another aspect of the present invention, a photo-initiator of about 1to about 3% by weight of composition is added to the second precursormaterial prior to the curing step.

The present invention step of curing includes cross-linking orpolymerization and the curing is mediated via heat, light, such as UVlight, or a combination thereof.

In still yet another aspect of the invention, the at least one cuttingedge structure formed using the method herein is a razor blade or aportion of a blade box and the razor blade or the blade box is securedinto a razor cartridge housing or frame.

Another embodiment of the present invention is a razor blade includingat least one cutting edge structure comprised of a polymeric material,the polymeric material produced by a precursor material for thepolymeric material. A still further embodiment is a blade box includingat least one cutting edge structure where the at least one non-cuttingedge structure is coupled to the at least one cutting edge structure,and both the cutting and non-cutting edge structures are made of apolymeric material, the polymeric material produced by a precursormaterial for the polymeric material.

The details of one or more embodiments of the invention are set forth inthe accompanying drawings and the description below. Other features,objects, and advantages of the invention will be apparent from thedescription and drawings, and from the claims.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts cross-sectional views of base structures of the priorart.

FIG. 2 is a flow diagram of a method of manufacturing razor blades frompolymer, according to a preferred embodiment of the present invention.

FIG. 3 is a micrograph of a steel blade used as a cutting edge templatein FIG. 2 according to the present invention.

FIG. 4 is a micrograph of a cross-sectional view of a cavity accordingto the present invention.

FIG. 5 is a micrograph of a replicated blade made with the process ofFIG. 2.

FIG. 6 is a front view of a razor cartridge having polymer razor bladesmade with the process of FIG. 2, according to one embodiment of thepresent invention.

FIG. 7 is a cross-sectional view of an alternate embodiment of thepresent invention depicting five cavities in a base structure.

FIG. 8 is a top view of a plurality of blade boxes in a base structure,each having a plurality of blades and a frame in another embodiment ofthe present invention.

FIG. 9 is a top view of a blade box for insertion into a razor cartridgeof the present invention.

FIG. 10 is a perspective view of a structure having a plurality ofnon-linear cutting edges formed therein according to a still furtherembodiment of the present invention.

FIG. 11 depicts various profiles of present invention cutting edgestructures.

DETAILED DESCRIPTION OF THE INVENTION

The methods of the present disclosure provide for the manufacture ofcutting edge structures (e.g., razor blades which may be used in shavingdevices or razors). Specifically, disclosed are methods formanufacturing cutting edges or razor blades for shaving devices frompolymeric material.

As used herein, a polymeric material signifies a material that is formedof a polymer, the latter being a large, chain-like molecule made up ofmonomers, which are small molecules. Generally, a polymer can benaturally occurring or synthetic. In the present invention, preferredembodiments comprise synthetic or semi-synthetic polymers. The syntheticor semi-synthetic polymer materials generally can occur in two forms orstates. The first state may be a soft or fluid state and the secondstate may be a hard or solid state. Generally synthetic polymers aremolded or extruded when in the first state (e.g., liquid or soft) andsubsequently formed into an object that is in a second state (e.g., hardor solid). In some instances, the material is reversible (e.g., amaterial in the second state can be converted back to its first state)while in others, the polymerization is irreversible (e.g., the materialcannot be converted back to its first state).

A thermoplastic polymer is a type of reversible polymer that is in asoft or liquid first state at elevated temperatures (e.g. 200° C. andabove) and converts to a solid second state when cooled to ambienttemperatures. Thermoplastic polymers are typically used for injectionmolding or extrusion techniques of the prior art.

For those polymeric materials where the second state is obtained fromthe first state via irreversible polymerization, the first state of thepolymeric material may generally be thought of as being a “precursor”for the second state of the polymeric material. As such, in the presentinvention, a polymeric material may be generated from a precursormaterial or a material in a first state.

The materials that are generally desired for the present inventioncutting edge structures are materials in the first, soft or liquid,states which comprise monomers or short chain length (e.g., or lowmolecular weight) polymers known as oligomers or both. Both monomers andoligomers are referred to herein as “precursors.” These precursors areconverted into long chain length polymeric material in the second, solidstate through a polymerization or cross-linking process, herein referredto as a curing process. Curing the precursor material can generally beachieved under the influence of heat, light, ionic or high energyradiation, or any combination thereof. After curing, the solid polymericmaterial is achieved.

FIG. 1 depicts cross-sectional views of base structures of the priorart. In one prior art embodiment, a base structure 10 is shown havingtwo parts, an upper portion 11 and a lower portion 12, while in anotherprior art embodiment, a base structure 13 is shown having a left portion14 and a right portion 15. Between the mating surfaces or interface 16of each prior art base structure is where a cutting edge structure 17may be formed. It should be noted that the base structure material ofthe prior art is generally machined out of metal. In both basestructures 10 and 13, in order for the cutting edge structure 17 to beformed, both portions of each base structure, respectively, have to bepresent in the base structure and have to be joined firmly together. Thebase structure is, in effect, a closed system only having one or moresmall fluid channels for the liquid polymer to be injected. Further, inboth base structures 10 and 13, after injecting and solidifying thepolymer, the base structure has to be opened or split apart in order toremove the cutting edge structure 17.

In FIG. 2, a flow diagram 20 of a method of manufacturing razor bladesfrom one or more polymeric materials according to a preferred embodimentof the present invention is illustrated.

A first polymeric material is preferably selected to produce a basestructure 110 in which to form the razor blades, as shown in step 100.There is generally no limitation to the types of first polymericmaterials that can be used to form the base structure 110. In apreferred embodiment, the first polymeric material and relatedprecursors are Poly (methyl methacrylate) (PMMA), Polydimethylsiloxane(PDMS), or other materials commonly used for micro-replication ornano-imprint lithography, and as such, the base structure 110 of step100 is preferably comprised of SYLGARD® 184 from Dow Corning. Theviscosity of SYLGARD® is about 5100 centiPoise.

A thermoplastic polymer may be utilized in the present invention forforming the base structure, particularly if the melting of the basestructure is desired as described below at step 600 in FIG. 2.

There is also no limitation with respect to the dimensions of the basestructure (e.g., height, length) though desirably the base structure mayhave a height of at least about 5 mm and a length of at least about 30mm.

It should be noted that the base structure 110 can be considered to be aportion of a mold that will form the cutting edge structure (e.g., razorblade). In the flow diagram 10 of the present invention, the basestructure 110 effectively represents a single part mold which cannotgenerally be split into further parts. The base structure 110 can beconsidered to be a half of a typical mold (e.g., the bottom half) sincethe other (e.g., upper) half is not a component of the presentinvention. This contrasts the base structures of the prior art shown inFIG. 1 by having only a single part mold or one half of a mold, theissues of “flashing” found in two part molds found in the prior art meltflow processing are avoided.

A cutting edge template 210 is pressed into the base structure 110 atstep 200. The cutting edge template 210 may be of any type desired, butis generally preferably a three-dimensional stainless steel blade of thetype shown in FIG. 3. The cutting edge template 210 may also becomprised of silicon, sapphire or diamond. The template 210, regardlessof material composition, may have any shape or profile feasible for acutting edge. For instance, the shape of the template, and in turn, thefinal cutting edge structure shape, may be straight, curved,ellipsoidal, notched or toothed, or with internal openings including asmany bevels and facets as desired to be present in the resultantpolymeric blade. Several shapes formed in the present invention areshown in FIGS. 10 and 11.

At step 300, the cutting edge template 210 is removed, revealing acavity 310 in the base structure 110. The cavity has the shape of therazor blade with desired tip radius (e.g., less than 1 μm). A micrographof a cross-sectional view of a cavity 310 as formed in step 300 using aPDMS base structure of the present invention is shown in FIG. 4.

It should be noted that, as shown in FIG. 2, the cavity is a single partcreated by replication of a template of a cutting edge. As noted above,by comprising only a single part mold or one half of a mold, the issuesof “flashing” found at the interface of two part molds in the prior artmelt flow processing are avoided.

As shown in step 400, the cavity 310 formed in the base structure 110made from a first polymeric material is filled with a second polymericmaterial 410, preferably in a form of a precursor for the secondpolymer. A precursor in the present invention may preferably be amonomer or a low molecular weight oligomer material.

Desirably the filling or pouring step 400 of the present inventionoccurs at ambient temperature ranging from about 10 degrees Celsius toabout 40 degrees Celsius or may be heated up to 100 degrees Celsius tofurther reduce its viscosity. While generally there is no limitation tothe types of second polymeric materials that can be used to fill thecavity, it is desirable that the polymeric precursor be more fluid andless viscous at ambient or near ambient temperatures than polymericmaterials used in melt flow processing in order to achieve fullpenetration of the material in the cavity 310 and to fill the cavity 310with a shape of a razor blade and tip desired. As such, a preferredviscosity of the second polymeric material precursor of the presentinvention is less than about 10000 centiPoise, more preferably less thanabout 5000 centiPoise, and most preferably about 3000 centiPoise orless. In the present invention, the second polymeric material ispreferably an acrylic based material, more preferably a polymer withmonomer or oligomer formulations such as Femtobond 4B, and mostpreferably polymeric materials from the ORMOCER® family, such asORMOCORE, supplied by Microresist Technology GmbH. The ORMOCORE materialhas a viscosity of about 2900 centiPoise at ambient temperature. Anothermaterial named E-shell 300 which may be used as a precursor has aviscosity of about 340 centiPoise. The precursor material has aviscosity that is lower than the viscosity of the base structure orfirst polymeric material. It is noted in the present invention that anon-polymerized material, such as Ormocore, may be heated, up to 100degrees Celsius to further reduce the viscosity. Generally, heatingabove 100 degrees Celsius may undesirably result in shrinkage whencooling down the cured structure.

Alternative, epoxy based materials such as SU8 supplied by MicroChemwith a range of viscosities from 2.5 to 1250 centiPoise can be utilizedas the second polymeric material.

A photo-initiator of about 1 to about 3% by weight of composition may beadded to the second polymeric material prior to the curing step 500 inFIG. 2. Photo-initiators generally start the polymerization orcross-linking (e.g., curing) process of the precursor of a polymericmaterial by absorbing radiation, commonly visible or UV light, andcreating radicals that react with the monomers or oligomers and linkthem together. A photo-initiator commonly used with acrylate basedprecursors is alpha hydroxy ketone, sold under the trade name ofIRACURE®184 by BASF. In the case of Ormocore, a photo-initiator may beIRACURE® 369 also by BASF.

The curing of the second polymeric material 410 to create a solidpolymer is performed at step 500 in FIG. 2. The curing process may beachieved by heat or light 520 though more preferably the curing processof the present invention is light. The temperature for curing may be anytemperature, including preferably ambient or room temperature. Desirablythe curing process of the present invention occurs at ambienttemperature ranging from about 10 degrees Celsius to about 40 degreesCelsius or may be heated up to 100 degrees Celsius to further reduce itsviscosity. Generally, the higher the temperature applied, the faster thecuring or hardening of the material occurs. Curing of the precursor(e.g., the monomer or oligomer to create a solid polymer) may involvepolymerization, i.e., molecular chain formation or cross-linking ofexisting molecular chains or both. Curing of the present invention iscarried out preferably by exposing the precursor or second polymericmaterial 410 to electromagnetic radiation, e.g., UV light. Thewavelength of the electromagnetic radiation may range from about 250 toabout 1500 nanometers, preferably from about 400 nanometers to about1100 nanometers. If a photo-initiator is used, the polymeric material istransparent at a specific wavelength in this range, optimally chosen forthe used photo-initiator. Hence, the precursor and the cured solidpolymer of the present invention and/or at least one side of the cavitygenerally need to be at least partially transparent for the wavelengthof the electromagnetic radiation to be effective. The transparencyselection of the polymer is necessary for effectiveness as curing orpolymerization of the whole object (e.g., cutting edge structure)generally cannot occur when using light if the light cannot penetratebelow the surface of the polymer. While light curing is preferred toavoid shrinkage, heat may also produce generally about the same resultsas those with light.

This step avoids expansion, shrinkage or distortion of the material andforms a cutting edge structure 510 from the second polymeric material410.

At step 600, the base structure 110 is removed from the cutting edgestructure 510. The base structure can be removed by physical or chemicalmeans. A physical removal may include bending the base structure 110apart and away from the cutting edge structure 510. In some cases, thebase structure 110 may have a rubbery attribute making a physicalremoval feasible. A chemical removal process may include dissolving thebase structure 110. The type of chemistry for dissolving the basestructure may include organic solvents and if made from PMMA may includesolvents such as acetone, acetonitrile, 1,2-dichloroethane, anddichlorobenzene, and if made from PDMA, may include solvents such assolution of TBAF (tetrabutylammonium fluoride) in NMP(N-Methylpyrrolidinone) or in DMF (dimethylformamide) or in THF(tetrahydrofuran) or in PMA (propylene glycol methyl ether acetate) orany combination thereof.

The removal process may be achieved by dissolving, wet etching (e.g.,via a chemical solution), melting, or any combination thereof.

The cutting edge structure 510 represents the structure in the shape ofa final cutting edge or razor blade edge.

It should be noted that in a preferred embodiment, the first polymericmaterial and related precursors that form the base structure 110 arePoly (methyl methacrylate) (PMMA) or Polydimethylsiloxane (PDMS). Thematerial to form the base structure is preferably compliant, signifyingthat the material is flexible or deformable, so that the replicatedcutting structure 510 formed from the second material, such as ORMOCOREor Femtobond 4B or SU8, can be easily removed from the base structure110 after curing. With a PDMS-formed base structure 110, the elasticityand low surface energy properties of the PDMS material allow desirableremoval of the cutting edge template 210. The elasticity providesdeformation of the base structure 110 to release the cutting edgetemplate 210 while also allowing the base structure 110 to return to itsoriginal shape after the cutting edge template 210 is removed. The lowsurface energy of the PDMS material prevents sticking of the cuttingedge template 210 to the base structure 110 and also prevents damage tothe base structure 110 during removal. Having these two properties, thebase structure material plays an advantageous role in assisting theremoval of the cutting edge template and cutting edge structure.

Flashing has been avoided with the present invention process since thebase structure of the present invention is capable of forming thepolymeric blade within one portion of the base structure as the basestructure is formed of one part as opposed to the two mating parts orhalves of the prior art (FIG. 1).

In FIG. 5 micrograph views are shown of actual released cutting edgestructures manufactured in accordance with the methods of manufacturingdescribed herein. The replicated cutting edge structure or blade edge ismade from ORMOCORE (the second polymeric material) removed from a PDMS(the first polymeric material base structure) mold using the process ofFIG. 2.

The tip radius of the cutting edge structure produced by the presentinvention process is desirably in the range of less than about 1micrometer. The hardness of a polymeric cutting edge structure formed,such as with ORMOCER®, may reach near 100 MPa after curing. In the caseof SU8, the cutting edge structure may be pyrolised after removing itfrom the base structure in step 800 of FIG. 2, to further increase thehardness. As polymerized SU8 has a hardness of about 180 MPa andpyrolised SU8 has a hardness of about 1 GPa.

As shown in FIG. 5, the razor blade 50 includes a polymeric body portionor substrate 52 with a wedge-shaped sharp edge having a tip 54. The tip54 has a blade edge 53 having about a 15 degree included blade angle 55,as shown in FIG. 5. Facets 56 and 58 diverge from the tip 54.

While a conventional razor blade wedge profile is shown in FIG. 5, thepresent invention contemplates cutting edge structures with any numberof facets, e.g., more than 2 or 3, and these facets need not be planar.Several exemplary shapes of the present invention are shown below inFIGS. 10 and 11 though any desirable, feasible shape is contemplated inthe present invention.

It should be noted that the base structure 110 of FIG. 2, if notdissolved or melted at step 600 to remove the cutting edge structure,may be used over again to form additional cutting edge structures. Thenumber of times the base structure may be used may be limited dependingon the type of first polymeric material utilized for the base structureand the robustness of the base structure after each use. Arrow 610 whichreturns back to step 300 of FIG. 2 depicts the re-use of the basestructure.

Once free from the base structure, each cutting edge structure that isproduced can generally be assembled individually into a razor cartridge.For example, one or more polymer razor blades may be adhered to bladesupports (e.g., with glue, ultrasonic welding) and assembled into razorcartridge housings. Once removed from the base structure, the blades canthen be processed or coated if necessary and assembled into a razorcartridge at step 700 of FIG. 2.

A razor cartridge 60 having one or more cutting edge structures or razorblades 62 made of polymer 64 of the present invention can be assembledas shown in FIG. 6. Razor cartridge 60 is similar to razor cartridgesthat are commercially available utilizing steel blades and with plastichousing and frame components 66. In assembly step 700, the polymericrazor blades 62 can be secured to a mounting assembly prior to beinginserted into the frame 66 or housing or they may be mounted directly onthe frame.

While the methods of manufacturing described herein have been referredto with primary reference to a single cutting edge structure (e.g.,razor blade), the methods are easily applicable to the manufacture ofmultiple cutting edge structures simultaneously.

In FIG. 7, a base structure 72 having a plurality of cavities 74 (e.g.,five cavities) produced in accordance with the methods described hereinis illustrated. Manufacture of the plurality of cutting edge structure(e.g., razor blades) follows the process of FIG. 2 but includes one ormore cutting edge templates (not shown) being pressed into the basestructure at the same time (if more than one) or in sequence (if onlyone). After such a “batch” manufacture of the plurality of cutting edgestructures such as razor blades on the base structure, the cutting edgestructures may be separated as described above in conjunction with FIG.2 in preparation for further assembly into razor cartridges. It shouldbe noted that the base structure 72 size, depending on the size of thecutting edge structures desired, may be larger than the base structure110 of FIG. 2.

Turning to FIG. 8, a plurality of razor blades 82 may be formedclustered together in groups of four blades with a small frame 84. Theframe is a non-cutting edge structure while the razor blades are cuttingedge structures. The clusters have a generally rectangular shape and forease in discussion are referred to herein as blade boxes 86. Theplurality of razor blades 82 can be manufactured in this clusteredorganization to reduce downstream process steps in the shaving razorsystem assembly. The blade boxes 86 have 4 individual razor blades 82,as illustrated, enclosed by a frame 84. The blade boxes 86 can bemanufactured identically or they can be different, such as each boxhaving differences in blade spacing, included blade angles, number ofblades, orientation of the blades, and the like. The differences can bemade via changes to the various method steps described above, such asutilizing different templates and pressing in different orientations,and the like. A blade box 86 can be removed from the base structure inthe same manner as described above, but such that the self-containedblade box 86 is a singular unitary part. In FIG. 9, a blade box 86 isinserted into an opening 92 in the housing 94 of a razor cartridge 90and secured therein or be formed into a razor cartridge entirely at theoutset (not shown).

Assembling the razor cartridge in such a manner eliminates the somewhattime consuming or difficult steps of affixing each individual razorblade to a blade support or to a housing, inserting each bladesupport-razor blade pair or each blade in the razor cartridge housing,and aligning each separate razor blade to the desired blade height,angle, and spacing. By utilizing the method described herein, theplurality of razor blades are aligned and secured in the blade box,thereby eliminating the need to affix individual blade supports and thedifficult process of aligning 3 or more separate razor blades into therazor cartridge housing. While FIG. 8 and FIG. 9 illustrates blade boxes86 having 4 razor blades, it is to be understood that any number ofrazor blades can be clustered together, such as 2, 3, 5, or more.

While the blades illustrated in the figures thus far have generallylinear blade edges, other blade shapes and edge patterns can be producedby the methods described herein.

To that end, in a still further alternative embodiment, differentcutting structures in addition to straight edged or wedge-shapedconfiguration for blade edges are also contemplated in the presentinvention.

These other shapes are produced by using a cutting edge template in step200 that comprises a different profile. In some instances, a sheet ofmaterial or a frame 153 with openings 154 that contain internal cuttingedges 152 that are non-linear as shown in the blade box 150 of FIG. 10is used. In this embodiment of the present invention, the sheet 153 maybe pressed into the base structure preferably using the process of FIG.2.

Any number of shapes or profiles for the cutting edge template, andhence, for the cutting edge structure or structures that will be formed,is contemplated in the present invention. The present inventionincludes, but is not limited to, the additional illustrative embodimentsdepicted in FIG. 11. Two arched cutting edge profiles, e.g., a gothicarch profile 162, a roman arch profile 164 are shown in FIG. 11 thoughany other feasible shape of the cutting edge structure is encompassed bythe present invention (e.g., wavy, serrations, saw teeth, etc.).Additionally, a cutting edge profile 166 having one or more undercuts167 is also shown in FIG. 11.

One of the many advantages of producing razor blades for shaving frompolymer in the manner described herein is that resultant cutting edgestructures or blade edges formed have very similar surface roughness asthe template cutting edge. Thus, when replicating a steel blade, grindmarks of the steel template cutting edge are also replicated. Verysmooth facet surfaces without grinding marks can be created, if thetemplate is produced from single crystal material such as silicon orsapphire. Accordingly, the resultant cutting edge structure has asimilar surface roughness to that of the template cutting edge. A changein the template cutting edge material would change the surface roughnessof the resultant cutting edge.

Accordingly, other embodiments are within the scope of the followingclaims.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method for manufacturing at least one cuttingedge structure comprising the steps of: providing a base structure of afirst polymeric material; pressing at least one cutting edge templateinto said base structure; removing said template to obtain at least onecavity in said base structure; filling said at least one cavity with asecond material, said second material being a precursor for a polymericmaterial; curing said second material; and separating said basestructure and said cured second polymeric material, said at least onecutting edge structure comprised of said cured second polymericmaterial.
 2. The method of claim 1, wherein said second precursormaterial is comprised of a monomer material, an oligomer material, orany combination thereof.
 3. The method of claim 1, wherein at least oneof the second precursor material, said cured second polymeric materialand at least one side of the cavity is transparent to electro-magneticradiation at a wavelength in the range of 250 to 1500 nanometers.
 4. Themethod of claim 1, wherein the separating step comprises physical orchemical removal of the base structure from the cured second polymericmaterial cutting edge structure.
 5. The method of claim 1, wherein aphoto-initiator of about 1 to about 3% by weight of composition is addedto the second precursor material prior to the curing step.
 6. The methodof claim 1, wherein said at least one cutting edge structure comprises agothic arch, a roman arch, or one or more undercuts.
 7. The method ofclaim 1, wherein a tip radius of said at least one cutting edgestructure is less than 1 micrometer.
 8. The method of claim 1, whereinsaid first polymeric material is comprised of Poly (methyl methacrylate)(PMMA) or Polydimethylsiloxane (PDMS).
 9. The method of claim 1, whereinsaid second precursor material is comprised of an acrylic based materialor epoxy based material.
 10. The method of claim 1, wherein a viscosityof said second precursor material is less than about 10000 centiPoise.11. The method of claim 1, wherein said base structure is comprised ofonly one part.
 12. The method of claim 1, wherein the at least onecavity is entirely comprised in a single part in said base structure.13. The method of claim 1, wherein a portion of the at least one cavityis not enclosed by said base structure after formation.
 14. The methodof claim 1, wherein the first polymeric material is compliant.
 15. Themethod of claim 1, wherein said separated base structure is reused atsaid filling step.
 16. The method of claim 1 wherein said step of curingcomprises cross-linking or polymerization.
 17. The method of claim 1,wherein said step of curing comprises heat, light, or any combinationthereof.
 18. The method of claim 17, wherein said curing step comprisesUV light.
 19. The method of claim 1, wherein said at least one cuttingedge structure is a razor blade or a portion of a blade box.
 20. Themethod of claim 19, further comprising the step of securing said razorblade or said blade box into a razor cartridge housing or frame.
 21. Themethod of claim 19 wherein said blade box is comprised of differenttypes of cutting edge structures.
 22. A blade box comprising at leastone cutting edge structure; at least one non-cutting edge structurecoupled to said at least one cutting edge structure, both said cuttingand non-cutting edge structures comprised of a polymeric material, saidpolymeric material produced by a precursor material for said polymericmaterial.
 23. A razor blade comprising at least one cutting edgestructure comprised of a polymeric material, said polymeric materialproduced by a precursor material for said polymeric material.